We sell authentic cuban cigars.


FROM BENCH TO BOX

Cuban Cigars

FROM BENCH TO BOX Every stage of making a Havana calls for skills of a high order and nowhere more so than at the work bench of the Torcedor; or cigar roller. He can roll a hundred and twenty Havanas a day, flawless and perfectly matched, which fit predetermined length and girth specifications to within the finest tolerances. Thanks to the dexterity of his sensitive fingers. The Pursuit of perfection continues. Expert hands match the cigars in perfect harmony within each box which then is dressed with colourful images. To some, this may seem a wasted journey for something that will vanish in a cloud of smoke. But for true cigar lovers, Havanas compare to a work of art.

TOBACCO PREPARATION:

On arrival from the Vuelta Abajo the Tercios, or bales, are unpacked. Each of the five types of leaf is treated differently before it is ready to go to the Galera, or roller's workshop.

WRAPPERS:

Their very delicate nature demands extra care to restore their supple silkiness before they are given a final classification and sorting. This is achieved by a special Moja, or moistening, performed only during the cool early morning hours. Excess water is shaken out and the leaves hung overnight to ensure the moisture is even. Next morning the expert, tender and caring hands of the Despalilladoras, or strippers, remove the stems whole, deftly bisecting the leaves. Next the Rezagadoras, or graders, sort them into piles according to size, colour and texture before the sorted leaves move on to the Galera.

FILLERS & BINDERS:

These leaves do not need moistening. The ageing of each of the four leaf types demands different periods of time. For example, the full flavoured Ligeros need to mature for two years or more while the lighter Volados and Capotes can be judged to be ready after twelve months. The Master Blender monitors the progress of each leaf type. Only when they reach to the Liga or blending department. Intense security surrounds the blending for it is here that the jealously guarded secret recipes for each Havana brand are held. Blends of leaves, sufficient to make 50 cigars, are issued to the Torcedores or rollers, literally "twisters".

CIGAR MAKING:

The Galera is the heart of any cigar factory. Here it is that the Torcedores, graded according to their ability, create the different brands and sizes. Their only tools, a wooden board, a sharp blade called a Chaveta, a guillotine, a pot of natural vegetable gum and, above all, their fingers. The average daily output of one of these craftsmen is 120 cigars.

QUALITY CONTROL:

Samples of each Torcedor's work in bundles of fifty cigars are regularly removed by the quality control team and checked for length, shape, girth, appearance and, above all, the weight. If the strict tolerances are not met the cigars are rejected. A serious matter for the Torcedores who are all paid on piece work.

CONDITIONING ROOM:

From the benches the cigars go into the factory's Escaparate, or conditioning room. This is a secure room lined with tall cedar cupboards. The cigars are shelved here for at least three weeks, sometimes for several months, under ideal conditions, i.e. between 18 degrees celsius 20 degrees celsius and 65% to 75% relative humidity. This environment enables them to lose some of the additional moisture gained during rolling.

COLOUR GRADING:

The final stages in the factory are dedicated to achieving a perfect presentation of the Havanas. First the Escogedor, or colour grader, sorts them into no fewer than 65 different shades. A second Escogedor sorts them into a part dressed or temporary cigar box, so that the finest tones range from dark to light, left to right. He also selects the best face of each cigar, the faces you see on opening a box of Havanas.

BANDING:

The Aniladora, or bander, takes the cigars out of the bands. In no circumstances may the Aniladora after the order or face chosen by the Escogedor. The band is placed on the selected face of each cigar which is then carefully replaced in the prescribed order of colour tones.

LABELING AND FINISHING:

The part-dressed boxes which were sent to be filled with cigars now return from the Anilado for their final embellishment, and affixing the all-important Government Warranty Seal. The boxes are made of cedarwood which allows the cigars to breathe and continue to mature. It has been some years in the making but at long last another fully finished box of Havanas is now ready of its journey to some far distant land where it will finally find a connoisseur's welcome.

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